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RE: Phill merchandize: 3D printing, removing supports and painting
It would, admittedly, not be very artisanal, but would it be feasible to derive a set of "negatives" from a model, with different openings for different colours? You would then have a set of reusable 3D masks for painting, perhaps even making spray painting possible. Just wondering.
Making the negatives is a comparatively easy task on a computer, and for mass production it could possibly be a solution . Doll makers sometimes use masking paper or modelling putty, to get a nice clean line. I have also seen custom made reusable masks, but they werent 3d printed.
Another solution (which I think is closer to what is done in industrial mass production of toys) could be to print in more than one part and then use different coloured plastics , or paint before assembly.